Electric Actuator Drive for Injection Molding Flow Control

ABSTRACT

Injection molding apparatus (1) comprising:an actuator (14, 940, 941, 942) comprising a rotor (940r, 941r, 942r) controllably rotatable by electric power, the actuator (14, 940, 941, 942) being interconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940d, 941d, 942d) comprising an interface that receives the drive signals (DC) and controllably distributes electrical energy or power in controllably varied amounts according to the drive signals (DC) to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r),a valve pin (1040, 1041, 1042) having an axis (X) and a control surface (43, 45, 102m) adapted to interface with a complementary surface (47, 103s) in a downstream feed channel to vary rate of injection fluid flow to a cavity of a mold, and,a sensor adapted to sense a property of the injection fluid upstream and away from a gate, the sensed property being used in a program to controllably position the control surface relative to the complementary surface.

RELATED APPLICATIONS

This application claims the benefit of priority to U.S. application Ser.No. 62/923,656 filed Oct. 21, 2019 and to U.S. application Ser. No.62/978,928 filed Feb. 20, 2020, the disclosures of both of which areincorporated by reference in their entirety as if fully set forthherein.

The disclosures of all of the following are incorporated by reference intheir entirety as if fully set forth herein: U.S. Pat. Nos. 5,894,025,6,062,840, 6,294,122 (7018), U.S. Pat. Nos. 6,309,208, 6,287,107,6,343,921, 6,343,922, 6,254,377, 6,261,075, 6,361,300 (7006), U.S. Pat.Nos. 6,419,870, 6,464,909 (7031), U.S. Pat. No. 6,062,840 (7052), U.S.Pat. No. 6,261,075 (7052US1), U.S. Pat. Nos. 6,599,116, 7,234,929(7075US1), U.S. Pat. No. 7,419,625 (7075US2), U.S. Pat. No. 7,569,169(7075US3), U.S. Pat. No. 8,297,836 (7087) U.S. patent application Ser.No. 10/214,118, filed Aug. 8, 2002 (7006), U.S. Pat. No. 7,029,268(7077US1), U.S. Pat. No. 7,270,537 (7077US2), U.S. Pat. No. 7,597,828(7077US3), U.S. patent application Ser. No. 09/699,856 filed Oct. 30,2000 (7056), U.S. patent application Ser. No. 10/269,927 filed Oct. 11,2002 (7031), U.S. application Ser. No. 09/503,832 filed Feb. 15, 2000(7053), U.S. application Ser. No. 09/656,846 filed Sep. 7, 2000 (7060),U.S. application Ser. No. 10/006,504 filed Dec. 3, 2001, (7068), U.S.application Ser. No. 10/101,278 filed Mar. 19, 2002 (7070) and PCTApplication No. PCT/US11/062099 (7100WO0) and PCT Application No.PCT/US11/062096 (7100WO1), U.S. Pat. Nos. 8,562,336, 8,091,202 (7097US1)and U.S. Pat. No. 8,282,388 (7097US2), U.S. Pat. No. 9,724,861(7129US4), U.S. Pat. No. 9,662,820 (7129US3), Publication No.WO2015006261 (7135WO0), Publication No. WO2014209857 (7134WO0),Publication No. WO2016153632 (7149WO2), International publication no.WO2016153704 (7149WO4), U.S. Pat. No. 9,205,587 (7117US0), U.S.application Ser. No. 15/432,175 (7117US2) filed Feb. 14, 2017, U.S. Pat.No. 9,144,929 (7118US0), U.S. Publication No. 20170341283 (7118US3),International Application WO2017214387 (7163WO0), InternationalApplication PCT/US17/043029 (7165WO0) filed Jul. 20, 2017, InternationalApplication PCT/US17/043100 (7165WO1), filed Jul. 20, 2017 andInternational Application PCT/US17/036542 (7163WO0) filed Jun. 8, 2017and International Application WO2018129015 (7169WO0), internationalapplication WO2018148407 (7170WO0), international applicationWO2018183810 (7171WO), international application WO2018175362,international application WO2018194961 (7174WO0), internationalapplication WO2018200660 (7176WO0), international applicationWO2019013868 (7177), international application WO2019100085 (7178WO0),international application WO 2020068285 (7182WO0), internationalapplication WO2020176479 (7185WO0).

BACKGROUND OF THE INVENTION

Injection molding systems have been developed for controlling fluid flowwith electric actuators and for controlling fluid flow upstream of thegate to the mold cavity as disclosed in U.S. Pat. Nos. 6,294,122 and6,464,909 and 7,597,828 and 7,029,268 and 7,234,929 the disclosures ofall of which are incorporated by reference as if fully set forth intheir entirety herein.

SUMMARY OF THE INVENTION

In accordance with the invention there is provided an injection moldingapparatus comprising:

an injection molding machine;

a controller arranged to generate drive signals or cause a generation ofdrive signals;

a manifold arranged to receive an injection material under pressure fromthe injection molding machine and to deliver at least some of theinjection material into a cavity of a mold;

a gate leading to the cavity of the mold;

a valve pin having a shaft, the shaft having an axis;

an actuator controllably drivable by electric power, the actuator havinga driver arranged to drive the valve pin wherein the valve pin isinterconnected at an upstream end to the actuator in an arrangement thatpermits the valve pin to be controllably drivable by the actuator alonga linear path of travel upstream and downstream through a downstreamfeed channel, the downstream feed channel arranged to receive anddeliver at least some of the injection material into the cavity, thevalve pin and the downstream feed channel being adapted to interfacewith each other to vary rate or velocity of flow of the injectionmaterial to and through the gate;

an electrical drive device having an interface arranged to receive thedrive signals and controllably distribute electrical energy to theactuator driver in controllably varied amounts according to the drivesignals; and

a pressure sensor arranged to sense pressure of the injection materialwithin a channel upstream and away from the gate, wherein the controlleris arranged to execute a program that receives signals from the pressuresensor indicative of the sensed pressure, the program havinginstructions that generate the drive signals based on the receivedsignals, the drive signals being sent to the driver via the electricaldrive device, the instructions controlling interfacing of the valve pinand the downstream feed channel to control the rate or velocity of flowof the injection material during the course of an injection cycle.

In such an apparatus, the program typically includes instructions thatutilize a position signal to adjust axial position of the valve pin by atravel distance or amount that causes interfacing of the valve pin withthe downstream feed channel to adjust real time pressure of theinjection material at one or more times over the course of the injectioncycle to a value that approaches or matches a predetermined targetpressure value for the one or more times over the course of theinjection cycle.

In such an apparatus the program can includes instructions that utilizea predetermined error value to determine the travel distance, thepredetermined error value corresponding or being proportional to one ormore of (a) an error in accuracy of the value of sensed pressure and (b)a difference in value between sensed pressure and the predeterminedtarget pressure.

In such an apparatus the valve pin and the downstream feed channel arepreferably adapted to interface with each other to vary rate or velocityof flow of injection material at an axial position upstream and awayfrom the gate.

In such an apparatus the pressure sensor preferably senses pressure ofthe injection material and is adapted to generate a signal indicative ofsensed pressure that is received at the controller, the instructionsbeing adapted to compare the sensed pressure to a target pressure andadjust axial position of the valve pin such that injection materialpressure is adjusted to track the target pressure.

In such an apparatus, the pressure sensor is preferably adapted to sensethe injection material pressure at a position downstream of an axialposition at which the valve pin and the downstream channel interfacewith each other to vary rate or velocity of flow of the injectionmaterial.

In such an apparatus the valve pin can include a control surface and thedownstream feed channel has a complementary surface adapted to interfacewith the control surface to controllably vary rate or velocity of flowaccording to controlled axial positioning of the control surfacerelative to the complementary surface of the downstream feed channel.

In such an apparatus the electrical drive device typically includes apulse-width modulator (PWM) that converts received electrical energy orpower into waveforms or duty cycles, each waveform or duty cycle beingadapted to drive a corresponding phase-coil of the actuator driver.

In such an apparatus the pulse-width modulator (PWM) can include aninverter or a comparator.

In such an apparatus the electrical drive typically includes one or theother or both of a digital signal receiving and transmitting device,wherein: the digital signal receiving and transmitting device is adaptedto receive and transmit digital signals between the electrical drive andthe controller of the injection molding apparatus, and wherein thedigital signals include one or more control signals, where the one ormore control signals are digital control signals received from thecontroller.

In such an apparatus the actuator can have a housing that houses thedriver, the housing being adapted to support the rotor, the electricaldrive device being housed within or by the housing or being mounted onor to the housing, and wherein the housing is mounted in proximity ordisposition relative to a heated manifold such that one or the other orboth of the housing and the electrical drive is or are in substantialheat communication or contact with the heated manifold.

In such an apparatus the housing of the actuator can be interconnectedto a linear travel converter in an arrangement wherein the valve pin isadapted to be driven along a linear axis (X) that is non coaxialrelative to a drive axis (Y), the linear travel converter being mountedon or to or disposed in heat conductive communication with the heatedmanifold.

In such an apparatus the valve pin can have an upstream end coupled tothe driver, a downstream end that closes the gate on downstream movementof the valve pin to a gate closed position, the control surface beingdisposed in a selected axial position intermediate the upstream anddownstream ends that is adapted to interact with the complementarysurface to decrease rate of material flow on upstream movement of thevalve pin through a selected path of travel and to increase rate ofmaterial flow on downstream movement of the valve pin through theselected path of travel.

In another aspect of the invention there is provided a method to performan injection molding cycle comprising:

providing, with an injection molding machine, an injection moldingmaterial under pressure,

providing a valve pin having a shaft, the shaft having an axis (X),

adapting the valve pin to interface with a downstream feed channel tovary rate or velocity of flow of the injection material to the mold,

receiving the injection molding material at a manifold,

directing, with a controller, a generation of drive signals adapted todrive a driver arranged to controllably drive the valve pin,

routing at least some of the injection material through the downstreamfeed channel into a cavity of a mold, said routing including:

providing a pressure sensor that senses pressure of the injectionmaterial upstream and away from the gate and sends signals indicative ofthe sensed pressure to the controller,

providing the controller with a program that generates the drive signalsbased on the pressure signals.

receiving the drive signals at an interface of an electrical drivedevice, controllably distributing electrical energy to the driver incontrollably varied amounts according to the drive signals received atthe interface.

In another aspect of the invention there is provided an injectionmolding apparatus comprising:

an injection molding machine,

a controller arranged to generate drive signals or cause a generation ofdrive signals,

a manifold arranged to receive an injection material under pressure fromthe injection molding machine and to deliver at least some of theinjection material into a cavity of a mold having a cavity,

a valve pin having a shaft, the shaft having an axis (X),

at least one actuator controllably drivable by electric power, theactuator having a driver arranged to drive the valve pin,

a controller arranged to generate drive signals or cause a generation ofdrive signals,

the valve pin being interconnected at an upstream end to the driver inan arrangement wherein the valve pin is controllably drivable by thedriver along a linear path of travel upstream and downstream through adownstream feed channel arranged to receive and deliver at least some ofthe injection material into the cavity, the valve pin and the downstreamfeed channel being adapted to interface with each other to vary rate orvelocity of flow of the injection material to and through a gate leadingto the cavity of the mold,

an electrical drive device having an interface arranged to receive thedrive signals and controllably distribute electrical energy to thedriver in controllably varied amounts according to the drive signals,

the electrical drive device and the controller being adapted to receiveand transmit digital signals between the electrical drive device thecontroller, wherein the digital signals include one or more drivesignals received by the electrical drive device from the controller,

the controller having a program that receives signals from one or moreof a pressure sensor that senses pressure of the injection material or aposition sensor that senses position of the actuator or the valve pin,the program having instructions that generate the drive signals based onthe received signals, the drive signals being sent to the driver via theelectrical drive device, the instructions controlling interfacing of thevalve pin and the downstream feed channel to control the rate orvelocity of flow of the injection material during the course of aninjection cycle.

In such an apparatus the digital control signals received by theactuator preferably include one or more of differential positioncommands, differential current commands, and differential velocitycommands.

In such an apparatus the digital signals can include one or morefeedback signals from the actuator to the controller corresponding tooperation of one or more of the actuator and the actuator driver.

In such an apparatus the valve pin and the downstream channel aretypically adapted to interface with each other to vary rate or velocityof flow of the injection material at an axial position upstream and awayfrom the gate.

In such an apparatus the actuator can have a housing that houses thedriver,

the electrical drive device being housed within or by the housing orbeing mounted on or to the housing,

wherein the housing is mounted in proximity or disposition relative to aheated manifold such that one or the other or both of the housing andthe electrical drive is or are in substantial heat communication orcontact with the heated manifold.

In such an apparatus the electrical drive device preferably includes apulse-width modulator (PWM) that converts received electrical energyinto waveforms or duty cycles, each waveform or duty cycle being adaptedto drive a corresponding phase-coil of the actuator driver.

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection fluid material (13) underpressure from the injection molding machine (500), a mold (25, 27, 300)having a cavity (5, 30) and at least one valve comprising:

an actuator (14, 940, 941, 942) comprising a rotor (940 r, 941 r, 942 r)controllably rotatable by electric power, the actuator (14, 940, 941,942) being interconnected to a controller (16) that generates digitalsignals (DC) that are received by a drive device that is (940 d, 941 d,942 d) mounted to or housed within an actuator housing (940 h, 941 h,942 h) that houses the rotor (940 r, 941 r, 942 r), the drive deviceutilizing the drive signals (DC) to control rotational movement of therotor (940 r, 941 r, 942 r),

a valve pin (1040, 1041, 1042) comprising a shaft having an axis (X) anda protrusion (102) disposed at a selected position along the axis of theshaft, the valve pin being interconnected at an upstream end to therotor in an arrangement wherein the valve pin is controllably drivablealong a linear path of travel (XX) upstream and downstream through adownstream feed channel (17, 19, 160, 940 c, 941 c, 942 c) that routesthe injection material to and through a gate leading to the cavity ofthe mold,

the protrusion (102) having a control surface (45, 102 m) and thedownstream feed channel having a complementary surface (47, 103 s)adapted to controllably vary rate of velocity of flow according tocontrolled axial positioning of the control surface (45, 102 m) of theprotrusion (102) relative to the complementary surface (47, 103 s) ofthe downstream feed channel (17, 19, 160, 940 c, 941 c, 942 c).

The actuator typically includes a driver (940 dr, 941 dr, 942 dr) thatreceives electrical energy or power from the drive device (940 d, 941 d,942 d), the drive device (940 d, 941 d, 942 d) comprising an interfacethat receives and controllably distributes electrical energy or power incontrollably varied amounts during the course of an injection cycle tothe driver (940 dr, 941 dr, 942 dr).

The actuator housing can be adapted to house the electrical drive (940d, 941 d, 942 d), the rotor (940 r, 941 r, 942 r) and the driver (940dr, 941 dr, 942 dr) and to support the rotor (940 r, 941 r, 942 r) suchthat the rotor is drivably rotatable, wherein the actuator housing (940h, 941 h, 942 h) is mounted in proximity or disposition relative to theheated manifold (40) such that one or the other or both of the housing(940 h, 941 h, 942 h) and the electrical drive (940 d, 941 d, 942 d) isor are in substantial heat communication with the heated manifold (40).

In another aspect of the invention there is provided an apparatus (1)comprising: an injection molding machine (500), a manifold (15) thatreceives an injection fluid material (13) under pressure from theinjection molding machine (500), a mold (25, 27, 300) having a cavity(5, 30) and at least one valve comprising:

an actuator (14, 940, 941, 942) comprising a rotor (940 r, 941 r, 942 r)controllably rotatable by electric power, the actuator (14, 940, 941,942) being interconnected to a controller (16) that generates controlsignals,

a drive device (940 d, 941 d, 942 d) interconnected to the controller(16), the drive device comprising an interface that receives andcontrollably distributes electrical energy or power in controllablyvaried amounts during the course of an injection cycle to a driver (940dr, 941 dr, 942 dr) for the rotor (940 r, 941 r, 942 r) according to thecontrol signals,

a valve pin (1040, 1041, 1042) comprising a shaft having an axis (X) anda protrusion (102) disposed at a selected position along the axis of theshaft, the valve pin being interconnected at an upstream end to therotor in an arrangement wherein the valve pin is controllably drivablealong a linear path of travel (XX) upstream and downstream through adownstream feed channel (17, 19, 160, 940 c, 941 c, 942 c) that routesthe injection material to and through a gate leading to the cavity ofthe mold,

the protrusion (102) having a control surface (45, 102 m) and thedownstream feed channel having a complementary surface (47, 103 s)adapted to controllably vary rate of velocity of flow according tocontrolled axial positioning of the control surface (45, 102 m) of theprotrusion (102) relative to the complementary surface (47, 103 s) ofthe downstream feed channel (17, 19, 160, 940 c, 941 c, 942 c).

In such an apparatus, the controller (16) can generate digital controlsignals (DC), the driver being adapted to receive and utilize thedigital control signals (DC) to control rotational movement of the rotor(940 r, 941 r, 942 r).

The drive device is (940 d, 941 d, 942 d) is typically mounted to orhoused within an actuator housing (940 h, 941 h, 942 h) that houses therotor (940 r, 941 r, 942 r).

The actuator housing is typically adapted to house the drive device (940d, 941 d, 942 d), the rotor (940 r, 941 r, 942 r) and the driver (940dr, 941 dr, 942 dr) and to support the rotor (940 r, 941 r, 942 r) suchthat the rotor is drivably rotatable, wherein the actuator housing (940h, 941 h, 942 h) is mounted in proximity or disposition relative to theheated manifold (40) such that one or the other or both of the housing(940 h, 941 h, 942 h) and the electrical drive (940 d, 941 d, 942 d) isor are in substantial heat communication with the heated manifold (40).

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection fluid material (13) underpressure from the injection molding machine (500), a mold (25, 27, 300)having a cavity (5, 30) and at least one valve comprising:

an actuator (14, 940, 941, 942) comprising a rotor (940 r, 941 r, 942 r)controllably rotatable by electric power, the actuator (14, 940, 941,942) being interconnected to a controller (16) that generates controlsignals that control distribution of electrical energy or power incontrollably varied amounts during the course of an injection cycle to adriver (940 dr, 941 dr, 942 dr) for the rotor (940 r, 941 r, 942 r)according to the control signals,

a valve pin (1040, 1041, 1042) comprising a shaft having an axis (X) anda protrusion (102) disposed at a selected position along the axis of theshaft, the valve pin being interconnected at an upstream end to therotor in an arrangement wherein the valve pin is controllably drivablealong a linear path of travel (XX) upstream and downstream through adownstream feed channel (17, 19, 160, 940 c, 941 c, 942 c) that routesthe injection material to and through a gate leading to the cavity ofthe mold,

the protrusion (102) having a control surface (45, 102 m) and thedownstream feed channel having a complementary surface (47, 103 s)adapted to (a) controllably vary rate of velocity of flow according tocontrolled axial positioning of the control surface (45, 102 m) of theprotrusion (102) relative to the complementary surface (47, 103 s) ofthe downstream feed channel (17, 19, 160, 940 c, 941 c, 942 c) and (b)such that reactive forces of the injection fluid material (13) againstthe valve pin (1040, 1041, 1042) enable use of an electric motor havinga maximum power or energy output of about.

Such an apparatus typically further comprises a drive device (940 d, 941d, 942 d) interconnected to the controller (16), the drive devicecomprising an interface that receives and controllably distributes theelectrical energy or power in controllably varied amounts during thecourse of an injection cycle to the driver (940 dr, 941 dr, 942 dr) forthe rotor (940 r, 941 r, 942 r) according to the control signalsgenerated by the controller (16).

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (18) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X) and a control surface (43, 45, 102m) disposed at a selected position along the axis (X) of the shaft, thevalve pin being interconnected at an upstream end to the rotor in anarrangement wherein the valve pin is controllably drivable along alinear path of travel (XX) upstream and downstream through a downstreamfeed channel (17, 19, 160, 940 c, 941 c, 942 c) that routes theinjection material to and through a gate (7, 9, 32, 34, 36) leading tothe cavity of the mold, the downstream feed channel having acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) to controllably vary rate or velocity of flowaccording to controlled axial positioning of the control surface (43,45, 102 m) relative to the complementary surface (47, 103 s) of thedownstream feed channel (17, 19, 160, 940 c, 941 c, 942 c).

The complementary surface (47, 103 s) is preferably disposed upstreamand away from the gate (7, 9, 32, 34, 36).

The electrical drive device (940 d, 941 d, 942 d) typically receiveselectrical energy or power from a power source (PS) and controllablydistributes the received electrical energy or power in controllablyvaried amounts during the course of an injection cycle to the driver(940 dr, 941 dr, 942 dr).

The electrical drive device (940 d, 941 d, 942 d) typically includes apulse-width modulator (PWM) that converts received electrical energy orpower into sinusoidal voltage waveforms or duty cycles, each sinusoidalvoltage waveform or duty cycle being adapted to drive a correspondingphase-coil of the actuator driver (940 dr, 941 dr, 942 dr).

The pulse-width modulator (PWM) typically comprises an inverter or acomparator.

The pulse width modulator (PWM) can comprise a three-phase inverter thatconverts electrical energy or power received from the interface intothree sinusoidal voltage waveforms or duty cycles, each one of the threesinusoidal voltage waveforms or duty cycles being adapted to drive acorresponding one of three phase-coils of the actuator driver.

The electrical energy or power received at or by the pulse widthmodulator (PWM) typically comprises a DC bus voltage.

The interface of the electrical drive (940 d, 941 d, 942 d) can beadapted to receive one or more control signals from a controller (16) ofthe injection molding apparatus (10) and to convert electrical energy orpower received from the power source (PS) into sinusoidal waveforms orduty cycles based on the one or more control signals.

The interface is typically comprised of the pulse width modulator (PWM)which converts electrical energy or power received from the power sourceinto sinusoidal waveforms or duty cycles based on the one or morecontrol signals.

The one or more control signals received by the interface can containcontrol information causing the pulse width modulator (PWM) to convertthe received electrical energy or power into sinusoidal waveforms orduty cycles adapted to drive the corresponding phase-coils of theactuator driver to adjust one or more of a position, a velocity ortorque of the actuator rotor (940 r, 941 r, 942 r).

The one or more control signals can comprise analog electrical signalsreceived at the electrical drive from the controller (16).

The electrical drive (940 d, 941 d, 942 d) typically comprises one orthe other or both of a digital signal receiving (16 r) and transmitting(16 s) device, wherein: the digital signal receiving and transmittingdevice is adapted to receive (16 r) and transmit (16 s) digital signalsbetween the electrical drive (940 d, 941 d, 942 d) and the controller(16) of the injection molding apparatus (10); and wherein, the digitalsignals include the one or more control signals, where the one or morecontrol signals are digital control signals received from thecontroller.

The digital control signals can include one or more of differentialposition commands, differential current commands, and differentialvelocity commands.

The digital signal receiving and transmitting device (16 r, 16 s) istypically adapted to receive digital signals from the actuator, whereinthe digital signals received from the actuator include one or morefeedback signals corresponding to operation of one or more of theactuator and the actuator rotor.

The pulse width modulator (PWM) typically converts the electrical energyor power received from the interface into sinusoidal waveforms or dutycycles adapted to drive the corresponding phase-coils of the actuatordriver based at least in part on the one or more feedback signals. Theone or more feedback signals received from the actuator can include oneor more of an incremental feedback signal and an absolute feedbacksignal.

The actuator typically has a housing (940 h, 941 h, 942 h) that housesthe rotor (940 r, 941 r, 942 r) and the driver (940 dr, 941 dr, 942 dr),the housing being adapted to support the rotor (940 r, 941 r, 942 r),the electrical drive device (940 d, 941 d, 942 d) being housed within orby the housing (940 h, 941 h, 942 h) or being mounted on or to thehousing (940 h, 941 h, 942 h), wherein the housing (940 h, 941 h, 942 h)is mounted in proximity or disposition relative to the heated manifold(40) such that one or the other or both of the housing (940 h, 941 h,942 h) and the electrical drive (940 d, 941 d, 942 d) is or are insubstantial heat communication or contact with the heated manifold (40).

The housing (940 h, 941 h, 942 h) can be mounted on or to a clampingplate (80) in an arrangement such that one or the other or both of thehousing (940 h, 941 h, 942 h) and the electrical drive (940 d, 941 d,942 d) are in substantial heat or thermal communication with the heatedmanifold (40).

The housing (940 h, 941 h, 942 h) of the actuator can be interconnectedto a linear travel converter (9401, 9411, 9421) in an arrangementwherein the valve pin (1040, 1041, 1042) is adapted to be driven along alinear axis (X) that is non coaxial relative to the drive axis (y), thelinear travel converter (9401, 9411, 9421) being mounted on or to ordisposed in heat conductive communication with the heated manifold (40).

The linear travel converter (9401, 9411, 9421) is mounted on or to oneor the other or both of the heated manifold (40) or a clamping plate(80).

The linear travel converter typically includes a converter housing (9401h) mounted in direct or indirect heat conductive contact to the heatedmanifold (40), the housing (940 h, 941 h, 942 h) being connected to theconverter housing (9401 h) in thermally conductive contact therewith.

The linear travel converter typically includes a converter housing (9401h) mounted on or to mounts comprised of a metal material that aremounted in direct metal to metal contact or communication with theheated manifold (40).

The valve pin (1040, 1041, 1042) can have an upstream end (1041 ue)coupled to the actuator, a downstream end (1041 de) that closes the gateon downstream movement of the valve pin to a gate closed position, thecontrol surface (43, 45, 102 m) being disposed in a selected axialposition intermediate the upstream (1041 ue) and downstream ends (1041de) that is adapted to interact with the complementary surface (103 s)to decrease rate of material flow on upstream movement of the valve pinthrough a selected path of travel (CP) and to increase rate of materialflow on downstream movement of the valve pin through the selected pathof travel (CP).

Such an apparatus typically includes a sensor (PS0, PS1, PS1 a, PS2, PS2a) that senses pressure of the injection material, the sensor (PS0, PS1,PS1 a, PS2, PS2 a) sending a signal indicative of sensed pressure to thecontroller (16), the controller including instructions that compare thesensed pressure to a target pressure and adjust axial position of thevalve pin such that material pressure is adjusted to track the targetpressure.

The sensor is preferably adapted to sense the injection materialpressure at a position downstream of the control surface of the valvepin.

The actuator typically includes a driver (940 dr, 941 dr, 942 dr) thatreceives electrical energy or power from the drive device (940 d, 941 d,942 d), the drive device (940 d, 941 d, 942 d) comprising an interfacethat receives and controllably distributes electrical energy or power incontrollably varied amounts during the course of an injection cycle tothe driver (940 dr, 941 dr, 942 dr).

The complementary surface (47, 103 s) and the control surface (43, 45,102 m) typically have a maximum diameter or radial dimension of about 12mm.

The complementary surface (47, 103 s) and the control surface (43, 45,102 m) can have a maximum diameter or radial dimension of about 10 mm.

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X), the valve pin beinginterconnected at an upstream end (1041 ue) to the rotor in anarrangement wherein the valve pin is controllably drivable by theactuator (14, 940, 941, 942) along a linear path of travel (XX) upstreamand downstream through a downstream feed channel (940 c, 941 c, 942 c),the valve pin and the downstream feed channel being adapted to interfacewith each other to vary rate or velocity of flow of the injectionmaterial to and through a gate (7, 9, 32, 34, 36) leading to the cavityof the mold, a sensor (PS0, PS1, PS1 a, PS2, PS2 a) that senses pressureof the injection material within a channel (17, 19, 940 c, 941 c, 942 c,5011) upstream of the gate (7, 9, 32, 34, 36), a controller (16)including a program that receives signals from the sensor indicative ofthe sensed pressure, the program generating instructions based on thereceived signals that are sent to the actuator (14, 940, 941, 942) viathe electrical drive device (940 d, 941 d, 942 d), the instructionscontrolling interfacing of the valve pin and the downstream feed channelto control the rate or velocity of flow of the injection material duringthe course of an injection cycle.

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin.

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected at an upstream end to the rotorin an arrangement wherein the valve pin is controllably drivable along alinear path of travel (XX) upstream and downstream through a downstreamfeed channel (17, 19, 160, 940 c, 941 c, 942 c) that routes theinjection material to and through a gate (7, 9, 32, 34, 36) leading tothe cavity of the mold, the downstream feed channel having acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected at an upstream end to the rotorin an arrangement wherein the valve pin is controllably drivable along alinear path of travel (XX) upstream and downstream through a downstreamfeed channel (17, 19, 160, 940 c, 941 c, 942 c) that routes theinjection material to and through a gate (7, 9, 32, 34, 36) leading tothe cavity of the mold, the downstream feed channel having acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X) and a control surface (43, 45, 102m), the valve pin being interconnected at an upstream end to the rotorin an arrangement wherein the valve pin is controllably drivable along alinear path of travel (XX) upstream and downstream through a downstreamfeed channel (17, 19, 160, 940 c, 941 c, 942 c) that routes theinjection material to and through a gate (7, 9, 32, 34, 36) leading tothe cavity of the mold, the downstream feed channel having acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m). the electrical drive (940 d, 941 d, 942 d)comprising one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin.

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to a driver (940 dr, 941 dr, 942 dr) that drivesthe rotor (940 r, 941 r, 942 r), a valve pin (1040, 1041, 1042)comprising a shaft having an axis (X), the valve pin beinginterconnected at an upstream end (1041 ue) to the rotor in anarrangement wherein the valve pin is controllably drivable by theactuator (14, 940, 941, 942) along a linear path of travel (XX) upstreamand downstream through a downstream feed channel (940 c, 941 c, 942 c),the valve pin and the downstream feed channel being adapted to interfacewith each other to vary rate or velocity of flow of the injectionmaterial to and through a gate (7, 9, 32, 34, 36) leading to the cavityof the mold, a pressure sensor (PS0, PS1, PS1 a, PS2, PS2 a) that sensespressure of the injection material within a channel (17, 19, 940 c, 941c, 942 c, 5011) upstream of the gate (7, 9, 32, 34, 36), a controller(16) including a program that receives signals from the pressure sensor(PS0, PS1, PS1 a, PS2, PS2 a) indicative of the sensed pressure, theprogram generating instructions based on the received signals that aresent to the actuator (14, 940, 941, 942) via the electrical drive device(940 d, 941 d, 942 d), the instructions controlling interfacing of thevalve pin and the downstream feed channel to control the rate orvelocity of flow of the injection material during the course of aninjection cycle, a position sensor (POS, POS0, POS1, POS2) that sends aposition signal (POS0 s, POS1 s, POS2 s) indicative of position of thevalve pin (1040, 1041, 1042) to the controller (16), the programincluding instructions that utilize the position signal to instruct theactuator (14, 940, 941, 942) to move the valve pin (1040, 1041, 1042) toone or more predetermined positions during the course of an injectioncycle.

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC),valve pin (1040, 1041, 1042) comprising a shaft having an axis (X) and acontrol surface (43, 45, 102 m), the valve pin being interconnected atan upstream end to the rotor in an arrangement wherein the valve pin iscontrollably drivable along a linear path of travel (XX) upstream anddownstream through a downstream feed channel (17, 19, 160, 940 c, 941 c,942 c) that routes the injection material to and through a gate (7, 9,32, 34, 36) leading to the cavity of the mold, the downstream feedchannel having a complementary surface (47, 103 s) adapted to interfacewith the control surface (43, 45, 102 m), the drive signals instructingthe rotor (940 r, 941 r, 942 r) to controllably drive the controlsurface (43, 45, 102 m) to one or more positions relative to thecomplementary surface (47, 103 s) such that rate or velocity of flow ofthe injection material is controllably variable, the actuator (940, 941,942) and the controller (16) being adapted to receive (16 r) andtransmit (16 s) digital signals between the actuator and the controller(16), wherein the digital signals include one or more control signalsreceived by the actuator (16 r) from the controller (16).

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (13) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising: an actuator (14, 940,941, 942) comprising a rotor (940 r, 941 r, 942 r) controllablyrotatable by electric power, the actuator (14, 940, 941, 942) beinginterconnected to a controller (16) that generates drive signals (DC), avalve pin (1040, 1041, 1042) comprising a shaft having an axis (X) and acontrol surface (43, 45, 102 m), the valve pin being interconnected atan upstream end to the rotor in an arrangement wherein the valve pin iscontrollably drivable along a linear path of travel (XX) upstream anddownstream through a downstream feed channel (17, 19, 160, 940 c, 941 c,942 c) that routes the injection material to and through a gate (7, 9,32, 34, 36) leading to the cavity of the mold, the downstream feedchannel having a complementary surface (47, 103 s) adapted to interfacewith the control surface (43, 45, 102 m), the drive signals instructingthe rotor (940 r, 941 r, 942 r) to controllably drive the controlsurface (43, 45, 102 m) to one or more positions relative to thecomplementary surface (47, 103 s) such that rate or velocity of flow ofthe injection material is controllably variable, the downstream feedchannel (17, 19, 160, 940 c, 941 c, 942 c) delivering injection materialto a further downstream channel (160, 942 c 2) having a channel axis (Y,Z) that is non coaxial relative to the linear path of travel (XX) of thevalve pin.

In such an apparatus, the downstream feed channel preferably has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) such that reactive upstream forces exerted onthe valve pin (1040, 1041, 1042) are minimized.

In such an apparatus the downstream feed channel typically has acomplementary surface (47, 103 s) adapted to interface with the controlsurface (43, 45, 102 m) at a position disposed upstream and away fromthe gate (32, 34, 36).

In such an apparatus the electrical drive (940 d, 941 d, 942 d) cancomprise one or the other or both of a digital signal receiving (16 r)and transmitting (16 s) device, wherein: the digital signal receivingand transmitting device is adapted to receive (16 r) and transmit (16 s)digital signals between the electrical drive (940 d, 941 d, 942 d) andthe controller (16) of the injection molding apparatus (10); andwherein, the digital signals include the one or more control signals,where the one or more control signals are digital control signalsreceived from the controller (16).

Such an apparatus can include a position sensor (POS, POS0, POS1, POS2)that sends a position signal (POS0 s, POS1 s, POS2 s) indicative ofposition of the valve pin (1040, 1041, 1042) to the controller (16), theprogram including instructions that utilize the position signal toinstruct the actuator (14, 940, 941, 942) to move the valve pin (1040,1041, 1042) to one or more predetermined positions during the course ofan injection cycle.

In such an apparatus the actuator (940, 941, 942) and the controller(16) can be adapted to receive (16 r) and transmit (16 s) digitalsignals between the actuator and the controller (16), wherein thedigital signals include one or more control signals received by theactuator (16 r) from the controller (16).

In such an apparatus the downstream feed channel (17, 19, 160, 940 c,941 c, 942 c) can be adapted to deliver injection material to a furtherdownstream channel (160, 942 c 2) having a channel axis (Y, Z) that isnon coaxial relative to the linear path of travel (XX) of the valve pin.

In another aspect of the invention there is provided a method ofperforming an injection molding cycle comprising operating any of theapparatuses described herein.

In another aspect of the invention there is provided an injectionmolding apparatus (1) comprising: an injection molding machine (500), amanifold (15) that receives an injection material (18) under pressurefrom the injection molding machine (500), a mold (25, 27, 300) having acavity (5, 30) and at least one valve comprising:

an actuator (14, 940, 941, 942) comprising a driver (940 dr, 941 dr, 942dr), the actuator (14, 940, 941, 942) being interconnected to acontroller (16) that generates drive signals (DC),

an electrical drive device (940 d, 941 d, 942 d) comprising an interfacethat receives the drive signals (DC) and controllably distributeselectrical energy or power in controllably varied amounts according tothe drive signals (DC) to the driver (940 dr, 941 dr, 942 dr) thatdrives the rotor (940 r, 941 r, 942 r),

a valve pin (1040, 1041, 1042) comprising a shaft having an axis (X) anda control surface (43, 45, 102 m) disposed at a selected position alongthe axis (X) of the shaft, the valve pin being interconnected to thedriver (940 dr, 941 dr, 942 dr) in an arrangement wherein the valve pinis controllably drivable along a linear path of travel (XX) upstream anddownstream through a downstream feed channel (17, 19, 160, 940 c, 941 c,942 c) that routes the injection material to and through a gate (7, 9,32, 34, 36) leading to the cavity of the mold,

the downstream feed channel having a complementary surface (47, 103 s)adapted to interface with the control surface (43, 45, 102 m) upstreamand away from the gate (7, 9, 32, 34, 36) to controllably vary rate orvelocity of flow according to controlled axial positioning of thecontrol surface (43, 45, 102 m) relative to the complementary surface(47, 103 s) of the downstream feed channel (17, 19, 160, 940 c, 941 c,942 c).

the valve pin being translationally drivable at a controllable rate oftravel between a start or fluid stop flow position, one or moreintermediate flow rate positions and a high flow rate position, thevalve pin being driven to the one or more intermediate flow ratepositions after withdrawal from the gate closed position to a secondposition and subsequently driven to a high flow rate position;

the apparatus including a position sensor adapted to sense the positionof the valve pin and send a signal indicative of the position of the pinto the controller;

the controller including instructions that instruct the driver to drivethe valve pin from the start or fluid stop position to the secondposition and subsequently to the high flow rate position on receipt bythe controller of a signal from the position sensor that is indicativeof the valve pin having reached the second position.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings contain numbering of components and devicesthat correspond to the numbering appearing in the foregoing Summary andfollowing description.

FIG. 1 is a schematic cross section of an injection molding systemcomprised of an electric or electronic actuator interconnected to ashortened valve pin without a downstream gate closing needle portion,the distal end of the shortened valve pin having a bulbous portion orprotrusion that has a flow control surface that interfaces with acomplementary control surface of a flow channel along a selectedposition upstream of and away from the gate to control the rate of flowof injection fluid upstream of the gate during the course of aninjection molding cycle, the electric or electronic actuators beinginterconnected to an electronic drive control device that is mounted tothe housing of the electric or electronic actuator, the electronic drivecontrol device receiving digital control and other signals from aremotely mounted controller containing a program that executes analgorithm for controlling operation of the electric or electronicactuator and the position of the valve pin within the flow channelduring the course of an injection cycle.

FIG. 2 is a side sectional schematic of a sequential valve gated systemsimilar to the FIG. 1 system showing three valves with extended pins andthat have electric or electronic actuators that have a drive controlmechanism that is integrated together with the body or housing of theactuator that houses the rotor and rotor drive components of theactuator.

FIG. 3 is a cross sectional view of one example of a valve pin assembly,the valve pin having an upstream protrusion having a control surface 102m that interfaces with a complementary inside surface 103 s of thedownstream flow channel that leads to the gate of the cavity, theupstream control surface of the pin being disposed in a flow openposition with respect to the complementary inside channel surface. And,in the position shown in FIG. 3, the downstream needle or shaftextension 1041 e of the pin 1041 is disposed in a gate closed orinjection material stopped position.

FIG. 3A is a closeup sectional view of the throat, control surface 102 mand complementary channel surface 103 s elements of the FIG. 3subassembly.

FIG. 3B is a is closeup sectional view of the distal valve and nozzle orgate ends of the FIG. 3 subassembly.

FIG. 4 is a view similar to FIG. 3 showing the valve pin componentdisposed in an intermediate upstream position relative to the positionshown in FIG. 3 where the rate of flow of injection material isrestricted by interfacing or interaction of the control surface 102 mand complementary surface 103 s and flow is enabled at the gate area 34with the tip end of the valve pin being withdrawn upstream from the gatesurface GS.

FIG. 4A is a closeup sectional view of the throat, control surface 102 mand complementary channel surface 103 s elements of the FIG. 4subassembly view.

FIG. 4B is a is closeup sectional view of the distal valve and nozzle orgate ends of the FIG. 4 view and subassembly.

FIG. 5 is is a view similar to FIG. 3 showing the valve pin componentdisposed in a throat closed position relative to the position shown inFIG. 3 where the rate of flow of injection material is stopped by matingof the maximum diameter portion or circumference of the control surface102 m and the complementary inside circumferential surface 103 s, andsuch that flow is enabled at the gate area 34 with the tip end of thevalve pin being withdrawn even further upstream from the gate surfaceGS.

FIG. 5A is an enlarged fragmentary sectional view of the throat, controlsurface 102 m and complementary channel surface 103 s elements of theFIG. 5 subassembly.

FIG. 5B is a is enlarged fragmentary sectional view of the distal valveand nozzle or gate ends of the FIG. 5 subassembly.

FIG. 5C is an enlarged fragmentary sectional view of a portion of anelbowed flow channel formed by the mating of a bore in an insert orbushing 40 i and a flow channel formed within a heated manifold 40. Inthis embodiment a valve pin 107 t is provided having a bulb or controlmember 102 having a control surface 102 t and a maximum diameter sectionhaving an outer circumferential surface 102 mds that mates with aninside complementary surface 103 s of the flow channel. In the FIG. 5Cview, the valve pin is disposed in an axial position where the maximumdiameter circumferential surface 102 mds is aligned and mated with thecomplementary surface such that flow of injection material is stopped.

FIG. 5D is a view similar to FIG. 5C showing the valve pin disposeddownstream of the throat section 103 t relative to the FIG. 5C positionin an axial position where the control surface 102 t of the pin isdisposed in an axial position where a gap 102 g is formed that restrictsflow to less than a maximum flow rate that occurs when the protrusion102 is moved fully downstream of the throat where flow is notrestricted. Flow rate can be controllably varied by moving the valve pindownstream from the FIG. 5C position through a select range ofdownstream travel relative to the throat 103 t.

FIG. 5E is a view similar to FIG. 5C showing the converse of FIG. 5Dwhere the valve pin is disposed upstream relative to the throat 103 tsuch that the control surface 102 t of the pin opens the flow channelupon upstream movement of the pin from the FIG. 5C position, and createsflow at a restricted rate over a select range of upstream path of travelby creating a restriction gap 103 g upstream of the throat 103 t, 103 tdthat is restricted relative to a gap that is created when the pin isfully withdrawn upstream where the control surface 102 t is in aposition that enables maximum flow.

FIG. 5F is an enlarged fragmentary cross-sectional view of anotherembodiment of an upstream away from the gate flow control pin surfaceand complementary channel surface where the pin has a conically shapedouter control surface that can be controllably disposed in a range ofaxial travel path positions relative to a complementary conicallyconfigured interior channel surface 103 s such that the size of a flowcontrol gap 102 g can be controllably varied thus enabling a varyingrate of flow of injection material. In this embodiment, the linear axisof travel XX of the valve pin 1041 is non coaxial relative to the axis Yof a downstream flow channel 160 that delivers injection material fromthe channel 941 c in which the valve pin 1041 is reciprocally drivenalong axis XX.

FIG. 5G is an enlarged fragmentary cross-sectional view of anotherembodiment of an upstream away from the gate flow control pin surfaceand complementary channel surface where the pin has a conically shapedouter control surface that can be controllably disposed in a range ofaxial travel path positions relative to a complementary conicallyconfigured interior channel surface 103 s such that the size of a flowcontrol gap 102 g can be controllably varied thus enabling a varyingrate of flow of injection material. In this embodiment, the linear axisof travel XX of the valve pin 1041 is non coaxial relative to the axesY, Z of downstream flow channels 160, 941 c 2 that delivers injectionmaterial from the channel 941 c in which the valve pin 1041 isreciprocally driven along axis XX.

FIG. 6 is a side sectional schematic view of one embodiment of anelectric actuator having an electric drive device mounted on, to orwithin the housing of the actuator and where the drive axis of theactuator is non coaxially arranged relative to the movement axis of thevalve pin, and is interconnected to a linear travel converter, the valvepin having a flow control bulb or protrusion, complementary channelsurface and controller with programming designed to enable pin positioncontrol based at least in part on matching pressure within the flowchannel to a predetermined profile of pressures.

FIG. 7 is a side sectional schematic view of another embodiment of anelectric actuator having an electric drive device mounted on, to orwithin the housing of the actuator and where the drive axis of theactuator is coaxially arranged relative to the movement axis of thevalve pin, the valve pin having a flow control bulb or protrusion,complementary channel surface and a controller with programming designedto enable pin position control based at least in part on matchingpressure within the flow channel to a predetermined profile ofpressures.

FIG. 8 is a side sectional schematic view of another embodiment of anelectric actuator having an electric drive device mounted on, to orwithin the housing of the actuator and where the drive axis of theactuator is non coaxially arranged relative to the movement axis of thevalve pin and is interconnected to a linear travel converter, theactuator housing is mounted to the top clamp plate, the valve pin havinga flow control bulb or protrusion, complementary channel surface and acontroller with programming designed to enable pin position controlbased at least in part on matching pressure within the flow channel to apredetermined profile of pressures.

FIG. 8A is a schematic side sectional view of the armature and drive rodcomponents of a linear drive proportional solenoid that can besubstituted for the assembly of rotary motion enabling components of therotary electric actuators described herein to enable direct linearactuation movement of the drive rod by the armature when energized withelectricity.

FIG. 9 is a side sectional schematic view of another embodiment of anelectric actuator having an electric drive device mounted on, to orwithin the housing of the actuator and where the drive axis of theactuator is non coaxially arranged relative to the movement axis of thevalve pin and is interconnected to a linear travel converter, theactuator housing is mounted to the linear travel converter housing whichis in turn mounted to the top clamp plate, the valve pin having a flowcontrol bulb or protrusion, complementary channel surface and acontroller with programming designed to enable pin position controlbased at least in part on matching pressure within the flow channel to apredetermined profile of pressures.

FIG. 9A is a schematic side sectional view of the armature and drive rodcomponents of a linear motor that can be substituted for the assembly ofrotary motion enabling components of the rotary electric actuatorsdescribed herein to enable direct linear actuation movement of the driverod by the armature when energized with electricity.

FIG. 10 is a side sectional schematic view of another embodiment of anelectric actuator having an electric drive device mounted on, to orwithin the housing of the actuator and where the drive axis of theactuator is non coaxially arranged relative to the movement axis of thevalve pin and is interconnected to a linear travel converter, theactuator housing is mounted to the top clamp plate, the valve pin havinga flow control bulb or protrusion, complementary channel surface and acontroller with programming designed to enable pin position controlbased at least in part on matching pressure within the flow channel to apredetermined profile of pressures.

FIG. 11a is one example of an injection cycle profile of pressure ofinjection material measured at a position immediately downstream of theaxial position within a fluid delivery channel as described herein wherea control surface of a valve pin in terfaces with a complementarysurface of the fluid delivery channel to vary a control flow gap.

FIG. 11b is another example of a profile similar to FIG. 11 a.

FIG. 11c is another example of a profile similar to FIG. 11 a.

FIG. 11d is another example of a profile similar to FIG. 11 a.

FIG. 12 is an example of a user interface displaying component andfunction fields that enable a user to display, use, create, edit andstore target pressure profiles.

FIG. 13 is another example of a user interface displaying component andfunction fields that enable a user to display, use, create, edit andstore target pressure profiles.

DETAILED DESCRIPTION

FIG. 1 is a schematic cross section of an injection molding systemcomprised of an electric or electronic actuator interconnected to avalve pin that has a flow control surface that interfaces with a surfaceof a flow channel at a selected position upstream of and away from thegate to control the rate of flow of injection fluid upstream of the gateduring the course of an injection molding cycle, the electric orelectronic actuators being interconnected to an electronic drive controldevice that is mounted to the housing of the electric or electronicactuator, the electronic drive control device receiving digital controland other signals from a remotely mounted controller containing aprogram that executes an algorithm for controlling operation of theelectric or electronic actuator and the position of the valve pin withinthe flow channel during the course of an injection cycle.

FIG. 2 shows a sequential valve gated system showing three valves thathave electric or electronic actuators that have a drive controlmechanism that is integrated together with the body or housing of theactuator that houses the rotor and rotor drive components of theactuator.

FIGS. 1, 2 show exemplary embodiments of injection molding systemsaccording to the present invention. The systems shown are multi-gatesingle cavity systems in which melt material 18 is injected into acavity 5, 30 from gates 32, 34, 36. Melt material 18 is injected fromthe barrel 500 of an injection molding machine 13 through an extendedinlet 5011 and into a heated distribution manifold 15, 40. Manifold 15,40 distributes the melt through upstream channels 17, 19. Although a hotrunner system is shown in which plastic melt is injected, the inventionis applicable to other types of injection systems in which it is usefulto control the rate at which a material (e.g., metallic or compositematerials) is delivered to a cavity. Melt is distributed throughchannels 17, 19 and into bores 940 c, 941 c, 942 c of nozzles 20, 21, 23respectively. Melt is injected out of nozzles 20, 21, 23 and intocavities 5, 30 (where the part is formed) which is formed by mold plates25, 27, 300. Although a multi-gate single-cavity system is shown, theinvention is applicable to, for example, multi-cavity systems.

The injection nozzles 20, 21, 23 are received in respective wells formedin the mold plates. The nozzles are typically each seated in supportrings that serve to align the nozzles with the gates 32, 34, 36 andinsulate the nozzles from the mold. An upstream end 1041 ue of the valvepins 1040, 1041, 1042 is connected to an associated actuator 14, 940,941, 942 that operate to drive the valve pins reciprocally upstream anddownstream through the delivery channels 940 c, 941 c, 942 c. The valvepin is opened at the beginning of the injection cycle starting from afully closed position as shown for example in FIGS. 3, 3B and returnedto a fully closed at the end of the cycle. During the cycle, the valvepin can assume intermediate positions between an upstream open position,in order to decrease or increase the rate of flow of the melt. In theembodiments shown, a protrusion or head 102 is disposed between anupstream end 1041 ue and downstream end 1041 de. The protrusion includesa tapered portion 102 m that forms an adjustably variable gap CGu, CGdwith a surface 103 s, 103 s 2 of the bore of the delivery channel of themanifold. Increasing or decreasing the size of the gap by displacing thevalve pin correspondingly increases or decreases the flow of meltmaterial to the gate. The valve pins 1040, 1041, 1042 can close and stopflow of injection fluid 18 in both a select upstream position as shownfor example in FIGS. 5, 5A and in a fully downstream gate closedposition as shown for example in FIGS. 3, 3B. When the valve pin 1040,1041, 1042 is closed in a downstream position, in the embodiment shownin FIGS. 3, 3B the downstream end 1041 de can be configured as a taperedportion as shown that contacts and seals with a complementary taperedgate surface GS. In alternative embodiments the gate surface can beconfigured in a cylindrical or other configuration to mate with acomplementarily cylindrically configured distal end surface 1041 de of avalve pin 940 c, 941 c, 942 c.

Melt flow rate is related to the material pressure sensed in a flowchannel. Thus, using the controller 16, the rate at which the melt flowsthrough the gates 32, 34, 36 and into the cavities can be controllablyadjusted during a given injection molding cycle, according to apredetermined desired pressure profile.

In one embodiment, FIGS. 3, 3A, 3B, 4, 4A, 4B, 5, 5A, 5B, to reduce therate or velocity of flow of melt 18, the pin 1041 can be retracted orcontrollably driven upstream away from the gate along a selected portionof a selected flow control path of travel CP as shown for example inFIGS. 4A, 5A by an actuator 940, 941, 942 to thereby controllablydecrease the width of a flow control gap CGd between the control surface102 m of the valve pin and the complementary control surface 103 s ofthe bore of the downstream channel 940 c, 941 c, 942 c. In this sameembodiment the rate or velocity of flow of melt 18 can be controllablyvariably increased by controllably driving the valve pin downstreamalong the selected portion of a selected flow control path of travel CP.

In an alternative embodiment, the rate or velocity of flow of melt 18can conversely be controllably increased by controllably driving thevalve pin 1041, FIGS. 3, 3A, 3B, 4, 4A, 4B, 5, 5A, 5B, upstream awayfrom the gate along another selected portion of a selected flow controlpath of travel beginning at and extending upstream of the throat 103 tto controllably increase the width of a flow control gap CGu between thecontrol surface 102 m of the valve pin and another complementary controlsurface of the bore of the downstream channel 940 c, 941 c, 942 c. Inthis alternative embodiment the rate or velocity of flow of melt 18 canbe controllably variably decreased by controllably driving the valve pindownstream along the same alternative selected portion of a selectedflow control path of travel.

In the FIGS. 3-5B embodiments, the valve pin includes an extension(1041) extending downstream from the control surface (43, 45, 102 m),the valve pin (1040, 1041, 1042) and the downstream feed channel (17,19, 160, 940 c, 941 c, 942 c) being configured such that in a firstdownstream position a distal end (1041 de) of the valve pin closes thegate (32, 34, 36) and the interface between the control surface (43, 45,102 m) and the complementary surface (47, 103 s) is not closed as shownin FIGS. 3-3B, and in a second upstream position, the distal end of thevalve pin (1041 de) does not close the gate (32, 34, 36) and theinterface between the control surface (43, 45, 102 m) and thecomplementary surface (47, 103 s) is closed as shown in FIG. 5-5B.

A material pressure transducer or sensor PS1, PS2, PS1 a, PS2 a can beused to sense the pressure of the injection material 18 either in thedelivery channel 940 c, 941 c, 942 c or within a fluid flow channel 17,19 disposed within the manifold 40 or within a bushing 940 b 1, 940 b 2having a fluid delivery channel that communicates with the downstreamfluid delivery channel 940 c, 941 c, 942 c.

In operation, the material 18 pressure is sensed by a pressure sensorPS0, PS0 a, PS1, PS2, PS1 a, PS2 a associated with each nozzle and iscommunicated in real time to a control system or controller 16. Thecontroller 16 receives the pressure signals, compares them to apredetermined profile of pressures over the course of an injection cycleand sends drive signals DC to the electrical drives 940 d, 941 d, 942 dthat controllably distributes electrical energy or power in controllablyvaried amounts according to the drive signals (DC) to the drivers 940dr, 941 dr, 942 dr that drive the rotors of the electric actuators. Thecontroller includes a processor and instructions that generate drivesignals DC that result in the valve pin 1040, 1041, 1042 being drivenupstream or downstream within a fluid delivery channel 940 c, 941 c, 942c to select positions during the course of an injection cycle so as tocause the pressure of the material 18 as measured in real time by thesensors PS0, PS1, PS2 to be adjusted to match or track the predeterminedprofile of preferred cycle material pressures such as in the examplesdescribed with reference to FIGS. 11-13.

FIGS. 5C-5E show an alternative melt flow controller embodiment in whicha pin 107 t is slidably mounted in a mounting channel 108 m having aprotrusion or bulbous portion 102 without a downstream needle extensionthat can close the gate 34. In such an embodiment, the control surface(43, 45, 102 m and complementary surface of the flow channel disposedupstream and away from the gate is the sole mechanism by which fluidflow is stopped at both the beginning and end of an injection cycle bypositioning the pin 107 t at a position as shown in FIG. 5C. As with thecontrol surface 43, 45, 102 m of FIGS. 5-5C, the control surface 43, 45,102 m of FIGS. 5C-5E has a diameter equal to the maximum diameter ofmidsection 102 md of the fluid contacting member 102 such that the pin107 t can be entirely withdrawn in the direction 107 u from the manifoldand bushing 108 t and readily replaced without disassembling any portionof the manifold or bushing 108 t. The maximum diameter midsection 102 mdtypically has the same or about the same diameter as the complementaryflow restricting throat surface 103 s of the bushing 108 t such thatwhen the two surfaces mate flow is stopped.

In the specific examples described herein, the control surface 43, 45,102 m is illustrated as circular circumferential surface of a bulb orbulbous protrusion 102. The control surface 43, 45, 102 m and itscomplementary channel surface 47, 103 s can be configured to have anygeometrical shape such as square, hexagonal, oval or the like other thancircular as long as the two surfaces can mate or engage each other suchthat flow of injection material is stopped when the two surfaces mate orengage with each other.

As shown in FIGS. 5D, 5E, the rate of flow and the size of the flow ratedetermining gap 103 g can be controllably varied by either upstreammovement 107 u, FIG. 5E or downstream movement, 107 d, FIG. 5D of pin107 t. Upstream movement 107 u can form gap 103 g between bushingsurface 108 g, FIG. 5E, and the lower outer control surface 102 t ofmember 102. Downstream movement 107 d, FIG. 5D, can also form a gap 103g between channel surfaces 103 s, 108 g and the upper portion of theouter control surface 102 t of member 102. As described above,controlled movement of pin 107 t by controller 16 controls the size ofthe gap 103 g and thus the rate of flow from upstream channel 160 todownstream channel 162 t which leads to downstream channel 190 or 200 orthe like. Axis X of pin 107 t as shown in FIGS. 5D-5F is not coaxialwith the axis of the downstream bore or flow channel such as channel 940c, 941 c, 942 c that leads at its distal end to a gate such as gate 32,34, 36.

FIG. 5F shows another embodiment of a valve having a pin that is noncoaxially arranged relative to the axis of a downstream channel thatdelivers fluid to a gate of a cavity of a mold. In the FIG. 5Fembodiment the valve pin 107 has a protrusion 102 with an outsidesurface 102 s which is complementary to a mating surface 103 disposeddownstream of the protrusion within the flow channel 160. When the twosurfaces mate, i.e. when the member 102 is in the position 102 p indashed lines in FIG. 5F, flow is stopped. Between the 102 p position andthe solid line 102 position shown in FIG. 2, the gap 102 g varies insize and the rate of fluid flow varies depending on the size of the gap.In this embodiment, the fluid flow rate decreases on forward upstreammovement 107 u of pin 107. Upstream movement of a fluid contactingmember, pin or the like means that the member moves against or in theopposite direction of the flow of the fluid. Downstream movement meansthat the member moves in the same direction as the flow of fluid.Upstream movement to decrease and/or stop flow rate is typicallypreferred. In the FIG. 5F embodiment, the rate of flow is increased byupstream movement of the fluid contacting member 102 and decreased bydownstream movement. And, the position at which fluid flow rate iscontrolled is located within a channel 162 a having an axis such as 104which is not coaxial with the downstream channels 941 c (not shown) thathave an axis that intersects a gate leading to a mold cavity.

The embodiments described control the rate of melt flow away from thegate along a channel axis offset from a channel having an axisintersecting and leading to a gate thus enabling control of flow rate tomultiple channels intersecting multiple gates. Controlling the melt flowaway from the gate also enables a pressure or other material conditionsensor to be located away from a gate.

In the FIGS. 3, 3A, 3B, 4, 4A, 4B, 5, 5A, 5B, 5C, 5D, 5E embodiments,the diameter 103 td of the throat surface 103 ts that is intended tomate with a complementary mating outer circumferential surface 102 md,102 mds of the pin 1041 has a maximum diameter of about 10 to 12 mm andpreferably a maximum diameter of about 8 to 9 mm such that upstreamreactive forces exerted by the injection fluid on the pin and upstreamto the motor rotor are minimized thus enabling use of a smaller sizedelectric motor actuator. In the FIGS. 5-5E embodiments, the diameter 102pd of the mating surface 102 mds of the pin 1041 is preferably adaptedto be the same or about the same as the diameter 103 td of the flowcontrol throat surface 103 ts such that when the pin 1041 is positionedin a position where the mating surface 102 mds is axially aligned withthe maximum diameter throat surface 103 ts, injection material flowthrough the throat 103 t, and thus through the gate 34, is stopped orsubstantially stopped.

The controller 16 typically comprises for example a PID controller and aCPU. The CPU can execute a PID (proportional, integral, derivative)algorithm which compares the sensed pressure (at a given time) from thepressure sensor or transducer to a target pressure (for the given time).The CPU instructs the PID controller to adjust the position of the valvepin 1040, 1041, 1042 to mirror the target pressure for that given timeby instructing the electric actuator via communication of control drivesignals DC through the electrical drive 940 d, 941 d, 942 d.

FIGS. 6, 7, 8, 8A, 9, 9A, 10 show various configurations of electricactuators having controllably drivable rotors that can be used inconjunction with the electric drive element 940 d, 941 d, 942 d and thecontroller 16 to effect communication of electrical control signals fromthe controller 16 to the electric driver elements 940 dr, 941 dr, 942 drof the actuator.

Linearly driven actuators or linear actuators can alternatively be usedin place of rotary electric actuators. One example of a linear actuatorthat uses electric energy to directly produce linear motion in insteadof rotary motion, is a proportional solenoid as shown in FIG. 8A thateffects analog positioning of a solenoid plunger or rod 940 ld,typically a pin driver, as a function of coil current contained in thearmature or driver 940 dr. Another linear actuator alternative is asolenoid or linear motor, FIG. 9A, that employs a flux carrying geometrythat can produce a high starting force on the plunger, pin driver or rod940 ld to cause the plunger, pin driver or rod 940 ld to be controllablydriven along the linear drive axis A. The resulting force (torque)profile as the solenoid progresses through its operational stroke isnearly flat or descends from a high to a lower value. The solenoid canbe useful for positioning, stopping mid-stroke, or for low velocitylinear actuation movement of the plunger or rod 940 ld, especially in aclosed loop control system, The proportional concept is more fullydescribed in SAE publication 860759 (1986) the disclosure of which isincorporated by reference in its entirety as if fully set forth herein.

The linear motor, FIG. 9A, produces a linear force along its drive axisA. A typical mode of operation is as in a Lorentz-type actuator, inwhich applied force is linearly proportional to applied current andmagnetic field. Thus a linear actuator 940, FIGS. 8A, 9A, that effectslinear driven movement of a rod, pin driver or plunger or equivalentelement 9401 d can be employed as an alternative to a rotary drivenelectric motor for interconnection to a valve pin 50, 1040 to effectcontrollable driven linear movement of the valve pin 50, 1040, 1041along its axis X of reciprocal movement as described hereinabove.

A linear actuator is particularly suited for use in a configurationwhere the drive axis of the actuator and the pin movement axis X arecoaxially arranged such as in the embodiments described with referenceto FIGS. 4, 5, 6, 7 and the like. A linear actuator as described can beused to drive any pin drive member 9401 d as an alternative to the rotorbased actuators described herein.

Although in the disclosed embodiments the sensed condition is preferablypressure, other sensed conditions can be used which relate to melt flowrate. For example, the position of the valve pin. Pressure is typicallymeasured by a pressure transducer that measures pressure of theinjection material directly or indirectly such as via measurement of theload on the valve pin via a load sensor. Alternatively a position sensorcould be used to feed back the sensed condition (position) to the PIDcontroller. In the same manner as explained above, the CPU would use aPID algorithm to compare the sensed condition to a programmed targetposition profile or load profile for the particular gate to the moldcavity, and adjust the valve pin accordingly.

Where a position sensor is used to generate a signal indicative of theposition of the pin, a sensor that senses position of the valve pindirectly can be used such as a Hall Effect sensor or a light sensor.Alternatively, a sensor that detects position of the rotor of theelectric actuator, such as an encoder, could be used to generate aposition signal that is indicative of the position of the valve pin.

As used in this application with regard to various monitoring andcontrol systems, the terms “controller,” “component,” “computer” and thelike are intended to refer to a computer-related entity, eitherhardware, a combination of hardware and software, software, or softwarein execution. For example, a component or controller may be, but is notlimited to being, a process running on a processor, a processor, anobject, an executable, a thread of execution, a program, and/or acomputer. By way of illustration, both an application running on aserver and the server can be a component. One or more components mayreside within a process and/or thread of execution and a component maybe localized on one computer and/or distributed between two or morecomputers.

Claimed methods of the present invention may also be illustrated as aflow chart of a process of the invention. While, for the purposes ofsimplicity of explanation, the one or more methodologies shown in theform of a flow chart are described as a series of acts, it is to beunderstood and appreciated that the present invention is not limited bythe order of acts, as some acts may, in accordance with the presentinvention, occur in a different order and/or concurrent with other actsfrom that shown and described herein. For example, those skilled in theart will understand and appreciate that a methodology couldalternatively be represented as a series of interrelated states orevents, such as in a state diagram. Moreover, not all illustrated actsmay be required to implement a methodology in accordance with thepresent invention.

In various embodiments of the invention disclosed herein, the term“data” or the like means any sequence of symbols (typically denoted “0”and “1”) that can be input into a computer, stored and processed there,or transmitted to another computer. As used herein, data includesmetadata, a description of other data. Data written to storage may bedata elements of the same size, or data elements of variable sizes. Someexamples of data include information, program code, program state,program data, other data, and the like.

As used herein, computer storage media or the like includes bothvolatile and non-volatile, removable and non-removable media for storageof information such as computer-readable instructions, data structures,program modules, or other data. Computer storage media includes RAM,ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digitalversatile disc (DVDs) or other optical disk storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium which can be used to store desired information andwhich can be accessed by the computer.

The methods described herein may be implemented in a suitable computingand storage environment, e.g., in the context of computer-executableinstructions that may run on one or more processors, microcontrollers orother computers. In a distributed computing environment (for example)certain tasks are performed by remote processing devices that are linkedthrough a communications network and program modules may be located inboth local and remote memory storage devices. The communications networkmay include a global area network, e.g., the Internet, a local areanetwork, a wide area network or other computer network. It will beappreciated that the network connections described herein are exemplaryand other means of establishing communications between the computers maybe used.

A computer may include one or more processors and memory, e.g., aprocessing unit, a system memory, and system bus, wherein the system buscouples the system components including, but not limited to, the systemmemory and the processing unit. A computer may further include diskdrives and interfaces to external components. A variety ofcomputer-readable media can be accessed by the computer and includesboth volatile and nonvolatile media, removable and nonremovable media. Acomputer may include various user interface devices including a displayscreen, touch screen, keyboard or mouse.

A “controller,” as used herein also refers to electrical and electroniccontrol apparatus that comprise a single box or multiple boxes(typically interconnected and communicating with each other) thatcontain(s) all of the separate electronic processing, memory andelectrical signal generating components that are necessary or desirablefor carrying out and constructing the methods, functions and apparatusesdescribed herein. Such electronic and electrical components includeprograms, microprocessors, computers, PID controllers, voltageregulators, current regulators, circuit boards, motors, batteries andinstructions for controlling any variable element discussed herein suchas length of time, degree of electrical signal output and the like. Forexample a component of a controller, as that term is used herein,includes programs, controllers and the like that perform functions suchas monitoring, alerting and initiating an injection molding cycleincluding a control device that is used as a standalone device forperforming conventional functions such as signaling and instructing anindividual injection valve or a series of interdependent valves to startan injection, namely move an actuator and associated valve pin from agate closed to a gate open position. In addition, although fluid drivenactuators are employed in typical or preferred embodiments of theinvention, actuators powered by an electric or electronic motor or drivesource can alternatively be used as the actuator component.

The injection molding machine IMM, 500, 13 typically includes its owninternal manufacturer supplied machine controller that generatesstandardized beginning of cycle gate closed and end of cycle gate openand gate closed machine voltage signals VS typically 0 volts for gateopen and 24 volts for gate open (or 0 volts and 120 volts respectively).The standardized machine voltage signals VS can be sent to a signalconversion device that converts the injection machine voltage signals toa signal usable by the controller 16 and the electric drive (940 d, 941d, 942 d) of an electric actuator to cause the electric actuator to movethe valve pin to a gate closed or gate open actuator position. Thecontroller (16) can utilize these start and end of injection cyclesignals together with position signals (POS0 s, POS1 s, POS2 s) that areindicative of position of the valve pin 1040, 1041, 1042 that aregenerated by a position sensor (POS0, POS1, POS2), to instruct anelectric actuator (940, 941, 942) to drive or move a valve pin to one ormore predetermined positions such as a start or end cycle position. Orthe position signals can be used by the controller to instruct theactuator to move or drive the valve pin to another intermediate positionduring the course of an injection cycle such as a position at which thepin serves to control rate of injection fluid flow or injection materialpressure such that the injection material is held at a “pack” phasepressure for a predetermined period of time prior to the end of thecycle when the gate to the cavity is closed.

The position sensor signals POS0 s, POS1 s, POS2 s and their associatedposition sensors POS, PS0, PS1, PS2, PS0 a, PS1 a, PS2 a can also beused as an input to a set of instructions included in the programcontained in controller 16 that operates to correct or adjust axialposition of the valve pin 1040, 1041, 1042 by a predetermined degreeeither upstream or downstream depending on the difference between thevalue of the target or predetermined pressure profile and the value ofthe real time pressure sensed at any given point in time during theinjection cycle. The degree of adjustment or correction in axialpositioning of the valve pin, and thus the precise positioning of theaxial positioning of control surface 102 m, 102 t is the degree oramount of travel distance that is required to reduce or increase thereal time pressure to match or to approach the value of thepredetermined target pressure at any given point in time during thecourse of the injection cycle. This degree of adjustment distance ispredetermined and is input to the program as a variable that is utilizedin the control program to send movement adjustment signals from thecontroller 16 to the electric drive 940 d, 941 d, 942 d for an actuator.The goal of the program is to instruct the actuators to drive the valvepins to an axial position over the course of the entire injection cyclethat produces a sensed or real time injection material pressure thatmatches the predetermined profile of target pressures as closely aspossible.

The program contained within the controller (16) can includeinstructions that utilize a position signal POS0 s, POS1 s, POS2 s toinstruct an actuator (14, 940, 941, 942) to move a corresponding valvepin (1040, 1041, 1042) to one or more predetermined positions during thecourse of an injection cycle that can include one or more of (a) aninitial position of the valve pin (1040, 1041, 1042) at start of theinjection cycle, (b) an end position of the valve pin at the end of theinjection cycle, and (c) one or more intermediate positions of the valvepin between the initial position and the end position.

The program can include instructions that utilize the position signal(POS0 s, POS1 s, POS2 s) to adjust sensed axial position of the valvepin by a travel distance or amount that causes the control surface (102m, 102 t) to adjust real time pressure of the injection material at oneor more times over the course of the injection cycle to a value thatapproaches or matches a predetermined target pressure value for the oneor more times over the course of the injection cycle.

The program can include instructions that utilize a predetermined errorvalue to determine the travel distance. The predetermined error valuetypically corresponds or is proportional to one or more of (a) an errorin accuracy of the value of sensed pressure and (b) a difference invalue between sensed pressure and the predetermined target pressure.

FIGS. 11a, 11b, 11c, 11d show time versus pressure graphs (235, 237,239, 241) of the pressure detected by four pressure transducersassociated with four nozzles mounted in a manifold block (not shown).The four nozzles can be substantially similar to or the same as thenozzles shown in FIGS. 1-5C and include pressure transducersinterconnected to a controller 16 as described herein. The FIGS. 11a-dplots are generated on a user interface 214 so that a user can observethe tracking of the actual pressure versus the target pressure duringthe injection cycle in real time, or after the cycle is complete. Thefour different graphs of FIGS. 11a-11d show as an example fourindependent target pressure profiles (“desired”) emulated by the fourindividual nozzles. Different target profiles are desirable to uniformlyfill different sized individual cavities associated with each nozzle, orto uniformly fill different sized sections of a single cavity. Graphssuch as these can be generated with respect to any of the previousembodiments described herein.

In the FIGS. 11a-11d example, the valve pin associated with plot 235 isopened sequentially at 0.5 seconds after the valves associated with theother three graphs (237, 239 and 241) were opened at 0.00 seconds. In asystem employing a pin configured with a flow control protrusion such as102 and associated flow control bore surface such as 103 s that aredisposed upstream and away from the gate together with an extendedneedle portion such as extension 1041 e, just before the pin is openedat the beginning of the cycle, the valve pins are in the position shownin FIGS. 5, 5A, 5B such that flow is stopped at the throat 103 t. Atapproximately 6.25 seconds at the end of the injection cycle all fourvalve pins are in the position shown in FIGS. 3, 3A, 3B where flow ofinjection material is stopped by the mating of the tip end 1041 de withthe gate surface GS at the gate 34. During injection (for example, 0.00to 1.0 seconds in FIG. 11b ) and pack (for example, 1.0 to 6.25 secondsin FIG. 11b ) portions of the plots, each valve pin is controlled to aplurality of positions such as FIGS. 4, 4A, 4B between the FIGS. 3 and 5to alter the pressure sensed by the pressure transducer PS0, PS1, PS1 a,PS2, PS2 a associated with each valve to track the target pressure.

Through the user interface 214, target profiles can be designed, andchanges can be made to any of the target profiles using standard windowsbased editing techniques. The profiles are then input to memory and usedby controller 16 to control the position of the valve pin. For example,FIG. 12 shows an example of a profile creation and editing screen icon300 generated on interface 214.

Screen icon 300 is generated by a windows-based application performed oninterface 214. Alternatively, this icon could be generated on aninterface associated with controller 6. Screen icon 300 provides a userwith the ability to create a new target profile or edit an existingtarget profile for any given nozzle and cavity associated therewith. Aprofile 310 includes (x, y) data pairs, corresponding to time values 320and pressure values 330 which represent the desired pressure sensed bythe pressure transducer for the particular nozzle being profiled. Thescreen icon shown in FIG. 12 is shown in a “basic” mode in which alimited group of parameters are entered to generate a profile. Forexample, in the foregoing embodiment, the “basic” mode permits a user toinput start time displayed at 340, maximum fill pressure displayed at350 (also known as injection pressure), the start of pack time displayedat 360, the pack pressure displayed at 370, and the total cycle timedisplayed at 380.

The screen also allows the user to select the particular valve pin theyare controlling displayed at 390, and name the part being moldeddisplayed at 400. Each of these parameters can be adjusted independentlyusing standard windows-based editing techniques such as using a cursorto actuate up/down arrows 410, or by simply typing in values on akeyboard. As these parameters are entered and modified, the profile willbe displayed on a graph 420 according to the parameters selected at thattime.

By clicking on a pull-down menu arrow 391, the user can select differentnozzle valves in order to create, view or edit a profile for theselected nozzle valve and cavity associated therewith. Also, a part name400 can be entered and displayed for each selected nozzle valve.

The newly edited profile can be saved in computer memory individually,or saved as a group of profiles for a group of nozzles that inject intoa particular single or multi-cavity mold. The term “recipe” is used todescribe a group of profiles for a particular mold and the name of theparticular recipe is displayed at 430 on the screen icon.

To create a new profile or edit an existing profile, first the userselects a particular nozzle valve of the group of valves for theparticular recipe group being profiled. The valve selection is displayedat 390. The user inputs an alpha/numeric name to be associated with theprofile being created, for family tool molds this may be called a partname displayed at 400. The user then inputs a time displayed at 340 tospecify when injection starts. A delay can be with particular valve pinsto sequence the opening of the valve pins and the injection of meltmaterial into different gates of a mold.

The user then inputs the fill (injection) pressure displayed at 350. Inthe basic mode, the ramp from zero pressure to max fill pressure is afixed time, for example, 0.3 seconds. The user next inputs the startpack time to indicate when the pack phase of the injection cycle starts.The ramp from the filling phase to the packing phase is also fixed timein the basic mode, for example, 0.3 seconds.

The final parameter is the cycle time which is displayed at 380 in whichthe user specifies when the pack phase (and the injection cycle) ends.The ramp from the pack phase to zero pressure will be instantaneous whena valve pin is used to close the gate, as in the embodiment of FIG. 13,or slower in a thermal gate (see FIG. 1) due to the residual pressure inthe cavity which will decay to zero pressure once the part solidifies inthe mold cavity.

User input buttons 415 through 455 are used to save and load targetprofiles. Button 415 permits the user to close the screen. When thisbutton is clicked, the current group of profiles will take effect forthe recipe being profiled. Cancel button 425 is used to ignore currentprofile changes and revert back to the original profiles and close thescreen. Read Trace button 435 is used to load an existing and savedtarget profile from memory. The profiles can be stored in memorycontained in the interface 215 or the controller 210. Save trace button440 is used to save the current profile. Read group button 445 is usedto load an existing recipe group. Save group button 450 is used to savethe current group of target profiles for a group of nozzle valve pins.The process tuning button 455 allows the user to change the PID settings(for example, the gains) for a particular nozzle valve in a controlzone. Also displayed is a pressure range 465 for the injection moldingapplication.

Button 460 permits the user to toggle to an “advanced” mode profilecreation and editing screen. The advanced profile creation and editingscreen is shown in FIG. 13. The advanced mode allows a greater number ofprofile points to be inserted, edited, or deleted than the basic mode.As in the basic mode, as the profile is changed, the resulting profileis displayed. The advanced mode offers greater profitability because theuser can select values for individual time and pressure data pairs. Asshown in the graph 420, the profile 470 displayed is not limited to asingle pressure for fill and pack, respectively, as in the basic mode.In the advanced mode, individual (x, y) data pairs (time and pressure)can be selected anywhere during the injection cycle.

To create and edit a profile using advanced mode, the user can select aplurality of times during the injection cycle (for example 16 differenttimes), and select a pressure value for each selected time. Usingstandard windows-based editing techniques (arrows 475) the user assignsconsecutive points along the profile (displayed at 478), particular timevalues displayed at 480 and particular pressure values displayed at 485.

The button 490 is used to select the next point on the profile forediting. Prev button 495 is used to select the previous point on theprofile for editing. Delete button 500 is used for deleting thecurrently selected point. When the delete button is used the twoadjacent points will be redrawn showing one straight line segment.

The add button 510 is used to add a new point after the currentlyselected point in which time and pressure values are entered for the newpoint. When the add button is used the two adjacent points will beredrawn showing two segments connecting to the new point.

Where a position sensor PS0, PS1, PS2 is included in the system tomeasure or monitor the position of a valve pin or actuator, theprocessor, memory, display or user interface (16) can be configured toinclude an algorithm that controls the position of the valve pin 1040,1041, 1042 based on signals generated by the positions sensors and sentto the controller 16, the signals being indicative of the position ofthe valve pin or actuator. The processor 16 can utilize the receivedposition signals in an algorithm that instructs the drivers of theactuator to move the valve pin initially from a gate closed position toone or more positions where the rate of fluid flow is at a reduced raterelative to a high rate of flow or a maximum rate of flow allowed by theinterfacing of the valve pin with the complementary control surface ofthe downstream feed channel. The algorithm can include instructions thatfurther trigger the driver to drive the valve pin to one or morepositions at which the flow rate of injection fluid is a high rate or amaximum rate of flow when the position sensor sends a signal to thecontroller and algorithm that the valve pin has reached a selected axialposition at which the fluid flow rate is reduced.

In a typical system 10 as shown in FIG. 2 an inlet 18 a feeds moltenmaterial 18 from an injection molding machine 13 to a distributionchannel 17, 19 of a manifold 40. The distribution channel 19 commonlyfeeds three separate nozzles 20, 21, 23 which all commonly feed into acommon cavity 30 of a mold 300. One of the nozzles 20 is controlled byactuator 940 and arranged so as to feed into cavity 30 at an entrancepoint or gate that is disposed at about the center 32 of the cavity. Asshown, a pair of lateral nozzles 21, 23 feed into the cavity 30 at gatelocations that are distal 34, 36 to the center gate feed position 32. Asshown in FIG. 2, position sensors PS0, PS1, PS2 are included for sensingthe position of the actuator rotor and their associated valve pins (suchas 1040, 1041, 1042) and feed such position information to processor 16(e.g., controller, microcontroller, microprocessor, or the like).

As shown in the FIG. 2 embodiment, fluid material is injected from aninjection machine into a distribution channel 19 (e.g., a manifoldrunner) and further downstream into the bores of the lateral nozzles 21,23 and ultimately downstream through the gates at the center and distalgate positions 32, 34, 36. At the beginning of the cycle the pins aredisposed in a stop fluid flow position such as shown in FIGS. 5, 5C.However in one embodiment, the pins 1041, 1042 can be initially tointermediate positions where, a gap 103 g is formed that restricts thevelocity of fluid material flow to a selected reduced rate on account ofthe restriction gap that is formed between the outer surfaces 102 t ofthe outer surface of the control surfaces of the pins 107 t and theinner surfaces 103 t of the complementary control surface of the channel1621. The intermediate restricted flow position remains small enough torestrict and reduce the rate of flow of fluid material through lateralgates at distal gate positions 34, 36 to a rate that is less thanmaximum flow velocity over a selected travel distance of the valve pin.

When the lateral gates at distal gate positions 34, 36 are opened andfluid material is allowed to first enter the mold cavity into the streamthat has been injected from center nozzle 20 past distal gate positions34, 36, the two streams mix with each other. If the velocity of thefluid material is too high, such as often occurs when the flow velocityof injection fluid material through lateral gates at distal gatepositions 34, 36 is at maximum, a visible line or defect in the mixingof the two streams will appear in the final cooled molded product at theareas where lateral gates at distal gate positions 34, 36 inject intothe mold cavity. By injecting at a reduced flow rate for a relativelyshort period of time at the beginning when the lateral gates at distalgate positions 34, 36 are first opened and following the time when fluidfirst enters the flow stream, the appearance of a visible line or defectin the final molded product can be reduced or eliminated.

Thus the position of one or more of the valve pins 1041, 1042 startinginitially from the stop flow position, FIG. 5C can be controlled viacontroller 16 to limit the rate of injection fluid flow at the beginningof the cycle to a reduced rate and subsequently driven upon detection ofthe position of the valve pin at a selected one of the reduced rateposition to one or more positions such as shown in FIG. 5E whereinjection fluid flow is at a high rate or maximum rate relative to thereduced rate so that injection fluid can flow into the cavity at a highrate or maximum rate to fill the cavity in a reduced amount of time.

What is claimed is:
 1. An injection molding apparatus comprising: aninjection molding machine; a controller arranged to generate drivesignals or cause a generation of drive signals; a manifold arranged toreceive an injection material under pressure from the injection moldingmachine and to deliver at least some of the injection material into acavity of a mold; a gate leading to the cavity of the mold; a valve pinhaving a shaft, the shaft having an axis; an actuator controllablydrivable by electric power, the actuator having a driver arranged todrive the valve pin wherein the valve pin is interconnected at anupstream end to the actuator in an arrangement that permits the valvepin to be controllably drivable by the actuator along a linear path oftravel upstream and downstream through a downstream feed channel, thedownstream feed channel arranged to receive and deliver at least some ofthe injection material into the cavity, the valve pin and the downstreamfeed channel being adapted to interface with each other to vary rate orvelocity of flow of the injection material to and through the gate; anelectrical drive device having an interface arranged to receive thedrive signals and controllably distribute electrical energy to theactuator driver in controllably varied amounts according to the drivesignals; and a pressure sensor arranged to sense pressure of theinjection material within a channel upstream and away from the gate,wherein the controller is arranged to execute a program that receivessignals from the pressure sensor indicative of the sensed pressure, theprogram having instructions that generate the drive signals based on thereceived signals, the drive signals being sent to the driver via theelectrical drive device, the instructions controlling interfacing of thevalve pin and the downstream feed channel to control the rate orvelocity of flow of the injection material during the course of aninjection cycle.
 2. An apparatus according to claim 1 wherein theprogram includes instructions that utilize a position signal to adjustaxial position of the valve pin by a travel distance or amount thatcauses interfacing of the valve pin with the downstream feed channel toadjust real time pressure of the injection material at one or more timesover the course of the injection cycle to a value that approaches ormatches a predetermined target pressure value for the one or more timesover the course of the injection cycle.
 3. An apparatus according toclaim 2 wherein the program includes instructions that utilize apredetermined error value to determine the travel distance, thepredetermined error value corresponding or being proportional to one ormore of (a) an error in accuracy of the value of sensed pressure and (b)a difference in value between sensed pressure and the predeterminedtarget pressure.
 4. An apparatus according to claim 1 wherein the valvepin and the downstream feed channel interface with each other to varyrate or velocity of flow of injection material at an axial positionupstream and away from the gate.
 5. An apparatus according to claim 1wherein the pressure sensor senses pressure of the injection material,the pressure sensor generating a signal indicative of sensed pressurethat is received at the controller, the instructions being adapted tocompare the sensed pressure to a target pressure and adjust axialposition of the valve pin such that injection material pressure isadjusted to track the target pressure.
 6. An apparatus according toclaim 1 wherein the pressure sensor is adapted to sense the injectionmaterial pressure at a position downstream of an axial position at whichthe valve pin and the downstream channel interface with each other tovary rate or velocity of flow of the injection material.
 7. An apparatusaccording to claim 1 wherein the valve pin includes a control surfaceand the downstream feed channel has a complementary surface adapted tointerface with the control surface to controllably vary rate or velocityof flow according to controlled axial positioning of the control surfacerelative to the complementary surface of the downstream feed channel. 8.An apparatus according to claim 1 wherein the electrical drive deviceincludes a pulse-width modulator (PWM) that converts received electricalenergy or power into waveforms or duty cycles, each waveform or dutycycle being adapted to drive a corresponding phase-coil of the actuatordriver.
 9. An apparatus according to claim 8 wherein the pulse-widthmodulator (PWM) includes an inverter or a comparator.
 10. An apparatusaccording to claim 1 wherein the electrical drive includes one or theother or both of a digital signal receiving and transmitting device,wherein: the digital signal receiving and transmitting device is adaptedto receive and transmit digital signals between the electrical drive andthe controller of the injection molding apparatus, and wherein thedigital signals include one or more control signals, where the one ormore control signals are digital control signals received from thecontroller.
 11. An apparatus according to claim 1 wherein the actuatorhas a housing that houses the actuator driver, the housing being adaptedto support the rotor, the electrical drive device being housed within orby the housing or being mounted on or to the housing, and wherein thehousing is mounted in proximity or disposition relative to a heatedmanifold such that one or the other or both of the housing and theelectrical drive is or are in substantial heat communication or contactwith the heated manifold.
 12. An apparatus according to claim 11 whereinthe housing of the actuator is interconnected to a linear travelconverter in an arrangement wherein the valve pin is adapted to bedriven along a linear axis (X) that is non coaxial relative to a driveaxis (Y), the linear travel converter being mounted on or to or disposedin heat conductive communication with the heated manifold.
 13. Anapparatus according to claim 1 wherein the valve pin has an upstream endcoupled to the driver, a downstream end that closes the gate ondownstream movement of the valve pin to a gate closed position, thecontrol surface being disposed in a selected axial position intermediatethe upstream and downstream ends that is adapted to interact with thecomplementary surface to decrease rate of material flow on upstreammovement of the valve pin through a selected path of travel and toincrease rate of material flow on downstream movement of the valve pinthrough the selected path of travel.
 14. A method to perform aninjection molding cycle comprising: providing, with an injection moldingmachine, an injection molding material under pressure, providing a valvepin having a shaft, the shaft having an axis (X), adapting the valve pinto interface with a downstream feed channel to vary rate or velocity offlow of the injection material to the mold, receiving the injectionmolding material at a manifold, directing, with a controller, ageneration of drive signals adapted to drive a driver arranged tocontrollably drive the valve pin, routing at least some of the injectionmaterial through the downstream feed channel into a cavity of a mold,said routing including: providing a pressure sensor that senses pressureof the injection material upstream and away from the gate and sendssignals indicative of the sensed pressure to the controller, providingthe controller with a program that generates the drive signals based onthe pressure signals. receiving the drive signals at an interface of anelectrical drive device, controllably distributing electrical energy tothe driver in controllably varied amounts according to the drive signalsreceived at the interface.
 15. An injection molding apparatuscomprising: an injection molding machine, a controller arranged togenerate drive signals or cause a generation of drive signals, amanifold arranged to receive an injection material under pressure fromthe injection molding machine and to deliver at least some of theinjection material into a cavity of a mold having a cavity, a valve pinhaving a shaft, the shaft having an axis (X), at least one actuatorcontrollably drivable by electric power, the actuator having a driverarranged to drive the valve pin, a controller arranged to generate drivesignals or cause a generation of drive signals, the valve pin beinginterconnected at an upstream end to the driver in an arrangementwherein the valve pin is controllably drivable by the driver along alinear path of travel upstream and downstream through a downstream feedchannel arranged to receive and deliver at least some of the injectionmaterial into the cavity, the valve pin and the downstream feed channelbeing adapted to interface with each other to vary rate or velocity offlow of the injection material to and through a gate leading to thecavity of the mold, an electrical drive device having an interfacearranged to receive the drive signals and controllably distributeelectrical energy to the driver in controllably varied amounts accordingto the drive signals, the electrical drive device and the controllerbeing adapted to receive and transmit digital signals between theelectrical drive device the controller, wherein the digital signalsinclude one or more drive signals received by the electrical drivedevice from the controller, the controller having a program thatreceives signals from one or more of a pressure sensor that sensespressure of the injection material or a position sensor that sensesposition of the actuator or the valve pin, the program havinginstructions that generate the drive signals based on the receivedsignals, the drive signals being sent to the driver via the electricaldrive device, the instructions controlling interfacing of the valve pinand the downstream feed channel to control the rate or velocity of flowof the injection material during the course of an injection cycle. 16.Apparatus according to claim 15 wherein the digital control signalsreceived by the actuator include one or more of differential positioncommands, differential current commands, and differential velocitycommands.
 17. Apparatus according to claim 15 wherein the digitalsignals include one or more feedback signals from the actuator to thecontroller corresponding to operation of one or more of the actuator andthe actuator rotor.
 18. Apparatus according to claim 15 wherein thevalve pin and the downstream channel are adapted to interface with eachother to vary rate or velocity of flow of the injection material at anaxial position upstream and away from the gate.
 19. Apparatus accordingto claim 15 wherein the actuator has a housing that houses the driver,the electrical drive device being housed within or by the housing orbeing mounted on or to the housing, wherein the housing is mounted inproximity or disposition relative to a heated manifold such that one orthe other or both of the housing and the electrical drive is or are insubstantial heat communication or contact with the heated manifold. 20.Apparatus according to claim 15 wherein the electrical drive deviceincludes a pulse-width modulator (PWM) that converts received electricalenergy into waveforms or duty cycles, each waveform or duty cycle beingadapted to drive a corresponding phase-coil of the actuator driver.